Most of the force that drives the hammer back is inside the powertube and just after it. Gas will want to take the least restrictive route to escape and outside of the powertube, there's a nice big channel below and a decent sized one above the hammer in the receivers. Inertia from the initial blow back of the gas inside the powertube is what causes the hammer to fly backwards.

If anything, if too much material was removed, it would cause a firing problem instead of recocking. If too much was removed, the hammer might not slide into the powertube correctly, catching the lip of the tube before it hits the valve pin.

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That's a very good observation. If too much material was removed, the Power Tube & the Rear Bolt would be loose fitting and rattle around. That would cause a much bigger problem then air escaping around the Rear Bolt.

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Great post Lord. Not much more than I can add to that.

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http://www.PureExcessIndustries.com
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I dont have any air to try cocking it first, but this is really going to suck if thats the problem...I have a perfectly working a5 and after i take it apart i have to cock it before I put the air in...Just seems like it would be really annoying somestimes..

shouldn't need to all the time.. it has happend to me a few times before but that's it

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Eyekon Aka Dan
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A5 with G36 Shroud + Mag + Folding Stock and G36 12" barrel
A5 with Saw Shroud + Stock 20" Fluted trinity
Tiberius 8 pistol

Wants: Tiberius 9